Tool and shell using induction heating

Abstract

A component forming tool for forming a component from a blank includes a die forming shell for forming the component from the blank. A first shell portion of the die forming shell is disposed at a first set of support elements and a second shell portion is disposed at a second set of support elements. The tool includes at least one induction heating coil for induction heating of a workpiece disposed within a cavity formed by the first and second shell portions. The first set of support elements may be configured to detachably engage with respective base support elements of the component forming tool, with the first set of support elements keyed to engage the base support elements to limit lateral movement of the first shell portion at the base support elements. The first set of support elements may include at least two layers of different materials.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
       1. A component forming tool for forming a component from a blank, said component forming tool comprising:
 a die forming shell for forming the component from the blank, said die forming shell comprising a first shell portion and a second shell portion; 
 wherein said first shell portion is located on a first set of support elements; 
 wherein said second shell portion is located on a second set of support elements; 
 a cavity formed by said first and second shell portions when said first and second shell portions are at least partially engaged together; 
 at least one induction heating coil for induction heating of a workpiece disposed within said cavity; 
 first base support elements; 
 wherein first support elements of said first set of support elements are detachably engaged with respective ones of said first base support elements so that said first shell portion is detachably attached at said first base support elements; and 
 wherein, with said first set of support elements engaged with said first base support elements, the engagement limits lateral movement of said first shell portion at said first base support elements. 
 
     
     
       2. The component forming tool of  claim 1 , wherein a forming surface of said die forming shell is coated with a coating to increase its electrical resistivity, and wherein said coating comprises at least one of (i) a diamond like coating, (ii) a carbon/carbon coating, and (iii) a non-electrically conductive coating. 
     
     
       3. The component forming tool of  claim 1 , wherein said first set of support elements comprises at least two layers of different materials that include at least one of (i) resistance heating materials in said first set of support elements and (ii) resistance heating elements, in order to provide conductive heating to the die forming shell that then conductively heats the blank to be formed. 
     
     
       4. The component forming tool of  claim 1 , further comprising second base support elements, wherein second support elements of said second set of support elements are detachably engaged with respective ones of said second base support elements so that said second shell portion is detachably attached at said second base support elements. 
     
     
       5. The component forming tool of  claim 1 , wherein said first set of support elements comprises generally linear support elements arranged generally parallel to one another. 
     
     
       6. The component forming tool of  claim 1 , wherein said first set of support elements comprises staggered non-linear support elements. 
     
     
       7. The component forming tool of  claim 1 , wherein said first set of support elements comprises at least two layers of different materials that are laser deposited or spray welded at said first shell portion. 
     
     
       8. A component forming tool for forming a component from a blank, said component forming tool comprising:
 a die forming shell for forming the component from the blank, said die forming shell comprising a first shell portion and a second shell portion; 
 wherein said first shell portion is located on a first set of support elements; 
 wherein said second shell portion is located on a second set of support elements; 
 a cavity formed by said first and second shell portions when said first and second shell portions are at least partially engaged together; 
 at least one induction heating coil for induction heating of a workpiece disposed within said cavity; and 
 wherein said first set of support elements comprises at least two layers of different materials that are at least one selected from the group consisting of (i) laser deposited at said first shell portion, (ii) spray welded at said first shell portion, (iii) welded at said first shell portion and (iv) brazed at said first shell portion. 
 
     
     
       9. The component forming tool of  claim 8 , wherein said second set of support elements comprises at least two layers of different materials that are laser deposited or spray welded at said second shell portion. 
     
     
       10. The component forming tool of  claim 8 , wherein a forming surface of said die forming shell is coated with a coating to increase its electrical resistivity, and wherein said coating comprises at least one of (i) a diamond like coating, (ii) a carbon/carbon coating, and (iii) a non-electrically conductive coating. 
     
     
       11. The component forming tool of  claim 8 , wherein said first set of support elements comprises at least two layers of different materials that include at least one of (i) resistance heating materials in said first set of support elements and (ii) resistance heating elements, in order to provide conductive heating to the die forming shell that then conductively heats the blank to be formed. 
     
     
       12. The component forming tool of  claim 8 , comprising a fluid line having a plurality of fluid discharge ports at or near said first shell portion, wherein said component forming tool provides pressurized fluid in said fluid line and wherein said pressurized fluid is discharged from said fluid discharge ports as high pressure fluid to assist in the regulation of said die forming shell.